Danfoss VLT® AutomationDrive Oper. Operating instructions

FC 300 Operating Instructions

Contents

! How to Read these Operating Instructions ......................... 3

" Approvals ............................................................................................. 4

" Symbols ............................................................................................... 5

" Abbreviations ........................................................................................ 5

! Safety Instructions and General Warning ........................... 7

" Disposal Instruction ............................................................................... 7

" Software Version ................................................................................... 7

" High Voltage Warning ............................................................................. 8

" Safety Instructions ................................................................................. 8

" Avoid Unintended Start ........................................................................... 8

" Safe Stop of FC 302 ............................................................................... 8

" IT Mains ............................................................................................... 9

! How to Install .................................................................................. 11

" How to Get Started ................................................................................ 11

" Accessory Bag ≤ 7.5 kW ......................................................................... 11

" Mechanical Installation ........................................................................... 13

" Electrical Installation .............................................................................. 14

" Removal of Knockouts for Extra Cables ..................................................... 14

" Connection to Mains and Earthing ............................................................ 14

" Motor Connection ................................................................................... 16

" Motor Cables ......................................................................................... 18

" Fuses ................................................................................................... 19

" Access to Control Terminals ..................................................................... 21

" Electrical Installation, Control Terminals .................................................... 21

" Basic Wiring Example ............................................................................. 22

" Connection Examples ............................................................................. 23

" Start/Stop ............................................................................................ 23

" Pulse Start/Stop .................................................................................... 23

" Speed Up/Down .................................................................................... 24

" Potentiometer Reference ......................................................................... 24

" Electrical Installation, Control Cables ........................................................ 2 5

" Switches S201, S202, and S801 .............................................................. 26

" Tightening Torque .................................................................................. 26

" Final Set-Up and Test ............................................................................. 27

" Additional Connections ........................................................................... 29

" Relay Option MCB 105 ............................................................................ 29

" Control of Mechanical Brake .................................................................... 32

" Motor Thermal Protection ........................................................................ 32

! How to Programme ........................................................................ 33

" Quick Setup .......................................................................................... 34

" Parameter Lists ..................................................................................... 37

" Parameter Selection ............................................................................... 38

! General Specifications .................................................................. 59

! Warnings and Alarms ................................................................... 65

" Warnings/Alarm Messages ...................................................................... 65

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MG.33.A6.02 - VLT is a registered Danfoss trademark

FC 300 Operating Instructions

! Index ................................................................................................... 73

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FC 300 Operating Instructions

How to Read these Operating Instructions

" HowtoReadtheseOperatingInstructions

These Operating Instructions will help you get started, install, program, and trou-

bleshoot your VLT

®

AutomationDrive FC 3 00.

The FC 300 comes in two shaft performance levels. FC 301 ranges from scalar (U/f) to VVC+,

and FC 302 ranges from scalar (U/f) to servo performance.

These Operating Instructions cover both FC 301 and FC 302. Where information covers both series,

we refer to FC 300. O therw ise, we refer specifically to either FC 301 or FC 302.

Chapter 1, How to Read these Operating

Instructions, introduces the manual and

informs you about the approvals, symbols, and

abbreviations used i n this literature.

Page divider for How to Read these Operating Instructions.

Chapter 2, Safety Instructions and General

Warnings, entails instructions on how to

handle the FC 300 correctly.

Page divider for Safety Instructions and General Warnings.

Chapter 3, How to Install, guides you through

mechanical and technical installation.

Page divider

for How to Install

Chapter 4, How to Programme,showsyou

how to operate and programme the FC 300

via the Local Control Panel.

Page divider for How to Programme.

Chapter 5, General Specifications, entails

technical data about FC 300.

Page divider for G eneral Specifications.

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FC 300 Operating Instructions

How to Read these Operating Instructions

Chapter 6, Troubleshooting, assists you in solving

problems that may occur when using FC 300.

Page divider for Troubleshooting.

Available literature for FC 300

- The VLT

®

AutomationDrive FC 300 Operating Instructions provide the necce ssary

information for getting the drive up and running.

- The VLT

®

AutomationDrive FC 300 D esign Guide entails all technical information about

the d rive and customer design and applications.

- The VLT

®

AutomationDrive FC 300 Profibus Operating Instructions provid e the information req u ired

for controlling, monitoring and programming the drive via a Profibus fie ldbus.

- The VLT

®

AutomationDrive FC 300 DeviceNet Operating Instructions provide the information required

for controlling, monitoring and programming the drive via a DeviceNet fieldbus.

- The VLT

®

AutomationDrive FC 300 MCT 10 Operating Instructions provide information

for installa tion and use of the software on a P C.

- The VLT

®

AutomationDrive F C 300 I P21 / TYP E 1 Instruction provides information

for installing the IP21 / TYPE 1 option.

- The VLT

®

AutomationDrive FC 300 24 V DC Backup Instruction provides information

for installing the 24 V DC Backup option.

Danfoss Drives technical literature is also available online at www.danfoss.com/drives.

" Approvals

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FC 300 Operating Instructions

How to Read these Operating Instructions

" Symbols

Symbols used in these Operating Instructions.

NB!:

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

Indicates default setting

" Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Autom atic Motor Adaptation AMA

Current limit I

LIM

Degrees Celcius °C

Direct current DC

Drive Depende nt D-TYPE

Electro Magnetic Compellability EMC

Electronic ThermAL Relay ETR

Frequency Converter FC

Gram g

Hertz Hz

Kilohertz kHz

Local Control Panel LCP

Meter m

Milli Henry Inductance mH

Milliampere mA

Millisecond, Second ms, s

Minute min

Motion Control Tool MCT

Motor Type Dependent M-TYPE

Nanofarad nF

Newton Meters Nm

Nominal motor current I

M,N

Nominal motor frequency f

M,N

Nominal motor power P

M,N

Nominal motor voltage U

M,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current I

INV

Revolutions Per Minute RPM

Second s

Torque l i m i t T

LIM

Volts V

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FC 300 Operating Instructions

How to Read these Operating Instructions

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FC 300 Operating Instructions

Safety Instructions and General Warning

" Disposal Instruction

Equipment containing electrical components may not be disposed

together with domestic waste.

It must be separate collected with Electrical and Electronic waste

according to local a nd currently valid legislation.

Caution

The FC 300 AutomationDrive DC li

nk capacitors remain charged after power has been

disconnected. To avoid an electrical shock hazard, disconnect the FC 300 from the mains

before carrying out maintenance. Wait at least as follows before doing service on the

frequency converter:

FC 300: 0.25 – 7.5 kW 4 minutes

FC 300: 11 – 22 kW 15 minutes

Be aware that there may be high

voltage on the DC link e ven when the LEDs are turned off.

FC 300

Operating Instructions

Software version: 3.5x

These Operating Instructions can be used for all FC 300 frequency converters with software

version 3.5x.

Thesoftwareversionnumbercanbeseenfromparameter15-43.

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FC 300 Operating Instructions

Safety Instructions and General Warning

" High Voltage Warning

The voltage of the FC 300 is dangerous whenever the converter is connected to mains.

Incorrect fitting of the motor or VLT may cause damage to th e equipment, serious

injury or death. Consequently, it is esse ntial to comply with the ins tructions in this

manual as well as local and national rules and safety regulations.

" Safety Instr uc tion s

• Make sure the FC 300 is properly connected to ea rth.

• Do not remove mains plugs or motor plugs while the FC 300 is connected to mains.

• Protect users against supply voltage.

• Protect the motor against overloading according to national and local regulations.

• Motor overload prote ction is not included in the default settings. To add this function, set parameter

1-90 Motor thermal protection to value ETR trip or ETR warning . For the North American market:

ETR functions provide class 20 motor overload protection, in accordance with NEC.

• The earth leakage current exceeds 3.5 mA.

• The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains.

" Before Commencing Repair Work

1. Disconnect FC 300 from mains

2. Disconnect DC bus terminals 88 and 89

3. Wait at least 15 m inutes

4. Remove motor cable

" Avoid Unintended S tart

While F C 300 is connected to mains, the motor can be started/stop ped u

sing digital

commands, bus commands, references or via the LCP.

• Disconnect the FC 300 from mains whenever pe rsonal safety considerations ma ke

it necessary to avoid unintended start.

• To avoid unintended start, always activate the [OFF] key be

fore changing parameters.

• Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the mains

supply, or lost motor connection may cause a stopped motor to start.

" Safe Stop of FC 302

The FC 302 can perform the Designated S afety Function Uncontrolled Stopping by removal of power. (as

defined by draft IEC 61800-5-2) or Stop Category 0 (

as defined in EN 60204-1). It is designed and approved

suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop.

Prior to integration and use of FC 302 Safe Stop in an installation, a thorough risk analysis

on the installation must be carried out in o rde r to d ete rm ine whether the FC 302 S afe Stop

functionality and safety category are app

ropriate and sufficient.

In order to install and use the Safe Stop fun

ction in accordance with the requirements of Safety

Category 3 in EN 954-1, the related inform ation and instructions of the FC 300 D esign Guide

MG.33.BX.YY must be followed ! The information and instructions of the Operating Instructions

are not sufficient for a correct and saf

euseoftheSafeStopfunctionality!

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FC 300 Operating Instructions

Safety Instructions and General Warning

General warning

Warning:

Touching the electrical parts may be fatal - even after the equipment has

been disconnected from mains.

Also make sure that other voltage inputs have been disconnected, such as load-sharing (linkage

of DC intermediate circuit), as well as the motor connection for kinetic back-up.

Using VLT AutomationDrive FC 300: wait at least 15 minutes.

Shorter time is allowe d o nly if indicated on the nameplate for the specific uni t.

Leakage Current

The earth leakage current from the FC 300 exceeds 3.5 mA. To ensure that the ea rth cable has

a good mechanical connection to the earth connection (terminal 95), the cable cross section

must be at least 10 mm2 or 2 rated earth wires terminated separately.

Residual Current Device

This product can cause a D.C. current in the protective conductor. Where a residual current device

(RCD) is use d for extra protection, only an RCD of Type B (time delayed) shall be used on the

supply side of this product. S ee also RCD Application Note MN.90.GX.02.

Protective earthing of the FC 300 and the use of RCD’s must always follow national and local regulations.

IT Mains

Do not connect 400 V frequency converters with RFI-filters to mains supplies with a

voltage between phase and e a rth of more than 440 V.

For IT mains and delta earth (grounded leg), mains voltage m ay ex-

ceed 440 V betwee n phase and earth.

Par. 14-50 RFI 1 can on FC 302 be used to disconnect the internal RFI capacitiors from the RFI

filter to ground. If this is done it will reduce the RFI performance to A2 level.

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FC 300 Operating Instructions

Safety Instructions and General Warning

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FC 300 Operating Instructions

How to Install

" About H ow to Install

This chapter covers mechanical and electrical installations to and from power

terminals and control card terminals.

Electrical installation of options is described in the corresponding Instructions.

" How to Get Started

You can carry out a quick and EMC-correct

installation of the FC 300 by following the

steps described below.

Read the safety instructions before

installing the unit.

Diagram showing basic installation including mains, motor,

start/stop key, and potentiometer for speed ad

justment.

"

Accessory Bag ≤ 7.5 kW

Find the following parts included in the FC

300 Accessory Bag.

1 + 2 only available in units with brake chopper.

There is only one relay connector for FC 301. (≤ 7.5 kW)

For DC link connection (loadsharing) the connector 1 can

be ordered separately (order number 130B1064).

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FC 300 Operating Instructions

How to Install

Accessory Bag ≤ 7.5 kW, IP 55

1 + 2 only available in units with brake chopper.

There is only one relay connector for FC 301.

(≤ 7.5 kW, IP55)

Accessory Bag 11-22 kW

There is only one relay connector for FC 301. (11-22 kW)

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FC 300 Operating Instructions

How to Install

" Mechanical Installation

" Mechanical mounting

1. Drill holes in accordance with the measurements given.

2. You must provide screws suitable for the surface on which you want to mount

the FC 300. Retighten all four screws.

FC 300 IP2 0 allows side-by-side ins tallation. Because of the need for cooling , there must be a

minimum of 100 mm free air passage above and below the FC 300.

The back wall must always be solid.

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FC 300 Operating Instructions

How to Install

" Electrical Installation

NB!:

Cables General

Always comply with national and local regulations on cable cross-sections.

Tightening-up Torque

FC size Cable for: Tightening up torque

0.25-7.5 kW Line, Brake resistor, load sharing Motor cable 0.5-0.6 Nm

1.8 Nm

11-15 kW Line, Brake resistor, load sharing Motor cable 1.8 Nm

11-15 kW Motor cable 1.8 Nm

Relay 0.5-0.6 Nm

Earth 2-3 Nm

" RemovalofKnockoutsforExtraCables

1. Remove cable entry fro

m the frequency converter (Avoiding foreign parts in the

frequency converter when removing knockouts)

2. Cable entry has to be supported around the knockout you intend to remove.

3. The knockout can now

be removed with a strong mandrel and a hammer.

4. Remove burrs from the hole .

5. Mount Cable entry on frequency converter.

" Connection to Mains and Earthing

NB!

:

The p lug connector for power can

be removed.

1. Make sure the FC 300 is properly earthed .

Connect to earth connection (terminal 95).

Use screw from the accessory bag.

2. Place plug connector 91, 92, 93 from the

accessory bag onto the terminals labelled

MAINS at the bottom of FC 300.

3. Connect mains wires to the mains

plug connector.

The earth connection cable c ross

section m us t be at least 1 0 mm

2

or 2 rated mains wires terminated

separately according to EN 50178.

The mains connection is fitted to the main

switch if this is included.

How to connect to mains and earthing (A2

and A3 enclosure).

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FC 300 Operating Instructions

How to Install

How to connect to mains and earthing (A5 enclosure).

How to connect to mains and earthing (B1

and B2 enclosure).

NB!:

Check that mains voltage corresponds

to the mains voltag e of the FC

300 name plate.

IT Mains

Do not connect 400 V frequency

converters with RFI-filters to mains

supplies with a voltage between phase

and earth of more than 440 V.

For IT mains and delta earth (grounded leg), mains

voltage may exceed 440 V between phase and earth.

Terminals for mains and earthing.

How to conne ct to mains and earthing with

disconnector (A5 enclosure).

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FC 300 Operating Instructions

How to Install

" Motor Connection

NB!:

Motor cable must be screened/armoure d.

If an unscreened/unarmoured cable

is used, some EMC requirements are

not complied with. For more information, see

EMC specifications in the VLT AutomationDrive

FC 300 Design Guid e.

1. Fasten decoupling plate to the b ottom of FC 300

with screws and washers from the accessory bag.

2. Attach motor cable to terminals 96 (U),

97 (V ), 98 (W).

3. Connect to earth connection (terminal

99) on decoupling plate with screws from

the accessory bag.

4. Insert plug connectors 96 (U), 97 (V), 98 (W)

and motor cable to termina ls labelled MOTOR.

5. Fasten screened cable to decoupling plate with

screws and washers from t he acces sory bag.

Motor connection ≤ 7.5kWIP20(A2andA3enclosures)

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FC 300 Operating Instructions

How to Install

Motor connection ≤ 7.5kWIP55/NEMAtype12

Motor connection 11-22 kW IP 21 / NEMA type

1 (B1 and B2 enclosures)

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FC 300 Operating Instructions

How to Install

No. 96 97 98 Motor voltage 0-100%

U V W of mains voltage.

3 wires out of motor

U1 V1 W1

W2 U2 V2

6 wires out of motor, Delta-connected

U1 V1 W1 6 wires out of motor, Star-connected

U2, V2, W2 to b e interconnected separately

No. 99 Earth connection

PE

All types of three-phase as ynchronous standard

motors can be connected to the FC 300 . Normally,

small motors are star-connected (230/40 0 V,

/Y). Large mot ors are normally delta-connected

(400/690 V,

/Y).Refertothemotornameplate

for correct connection mode and voltage.

NB!:

In m otors without phase insulation paper or other insulation reinforcement suitable for operation

with voltage supply (such as a frequency converter), fit an LC filter on the output of the FC 300.

" Motor Cables

See chapter General Specifications for correct dimensio ning of motor cab le cross-section and length.

• Use a screened/armoured motor cable to comply with EMC emission specifications

unless otherwise s

tated f or the RFI filter used.

• Keep the motor cable as short as possible to reduce the n oise level and leakage currents.

• Connect the motor cable screen to the decoupling plate of the FC 300 and to the metal cabinet of the motor.

• Make the screen conne

ctions with the largest possible surface area (ca ble clamp). This is

done by using the supplied installation devices in the FC 3 00.

• Avoid mounting with twisted screen ends (pigtails), which will spoil high frequency screening effects.

• If it is necessary to

split the screen to install a motor isolator or motor relay, the screen must

be continued with the low est possible high frequency im ped a nce .

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FC 300 Operating Instructions

How to Install

" Fuses

Branch circuit protection:

In order to protect the ins tallation agains t electrical and fire hazard, all branch circuits in

an installation, switch gear, machines etc., must be shortcircuit and overcurrent protected

according to the national/international regulations.

Short circuit protection:

The frequency converter must be protected against short-circuit to avoid electrical or fire hazard.

Danfoss recommends using the fuses mentioned below to protect service personnel or other

equipment in case of an internal failure in the drive. The frequency converter provides full short

circuit protection in case of a short-circuit on the motor output.

Over current protection:

Provide overload protection to avoid fire hazard due t o overheating of the cables in the installa

tion.

The frequency converter is equipped with an internal over current protection that can be used

for upstream overload protection (UL-applications excluded ). See par. 4 -18. Moreover, fuses or

circuit breakers can be used to provide the over current protection in the installation. Ove

r current

protection must always be carried out according to na tional regulations.

Fuses must be designed for protection in a circuit capable of supplying a maximum of

100,000 A

rms

(symmetrical), 500 V maximum.

Non UL compliance

If UL/cU L is not to be complie d with, we

recommend using the following fuses, w

hich will

ensure compliance with EN50178:

In case of malfunction, not following the

recommendation may result in unneces

sary

damage of the frequency converter.

FC 30X Max. fuse size Voltage Type

K25-K75 10A

1)

200-240 V type gG

1K1-2K2 20A

1)

200-240 V type gG

3K0-3K7 32A

1)

200-240 V type gG

K37-1K5 10A

1)

380-500 V type gG

2K2-4K0 20A

1)

380-500 V type gG

5K5-7K5 32A

1)

380-500 V type gG

11K 63A

1)

380-500 V type gG

15K 63A

1)

380-500 V type gG

18K 63A

1)

380-500 V type gG

22K 80A

1)

380-500 V type gG

1) Max. fuses - see national/inte rnational

regulations for selecting an applicable fuse s ize.

UL Comp lian c e

200-240 V

FC 30X Bussmann Bussmann Bussmann SIBA Littel fuse

Ferraz-

Shawmut

Ferraz-

Shawmut

kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1

2-7.5 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10 ATM-R10 A2K-10R

1.1-2.2 KTN-R20 JKS-20 JJN-20 5017906-020 KLN-R20 ATM-R20 A2K-20R

3.0-3.7 KTN-R30 JKS-30 JJN-30 5012406-032 KLN-R30 ATM-R30 A2K-30R

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FC 300 Operating Instructions

How to Install

380-500 V, 525-600 V

FC 30X Bussmann Bussmann Bussmann SIBA Littel fuse

Ferraz-

Shawmut

Ferraz-

Shawmut

kW Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1

0.37-1.5 KTS-R10 JKS-10 JJS-10 5017906-010 KLS-R10 ATM-R10 A6K-10R

2.2-4.0 KTS-R20 JKS-20 JJS-20 5017906-020 KLS-R20 ATM-R20 A6K-20R

5.5-7.5 KTS-R30 JKS-30 JJS-30 5012406-032 KLS-R30 ATM-R30 A6K-30R

11.0 KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 A6K-40R

15.0 KTS-R50 JKS-50 JJS-50 5014006-050 KLS-R50 A6K-50R

18.0 KTS-R60 JKS-60 JJS-60 5014006-063 KLS-R60 A6K-60R

22.0 KTS-R80 JKS-80 JJS-80 5014006-100 KLS-R80 A6K-80R

KTS-fuses from Bussmann may substitute KTN for 240 V frequency converters.

FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters.

KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V frequency converters.

L50S fuses from LITTEL FUSE may substitute L50S fuses for 24 0 V frequency converters.

A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters.

A50X fuses from FERRAZ S HAWMUT may substitute A 25X for 240 V frequency converters.

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